Waste to fuel processes, systems, methods, and apparatuses

ABSTRACT

Production processes are provided that can include exposing a carbon-based material to liquid media to form hydrocarbon fuel. Waste to fuel conversion processes as well as waste material processing reactors are provided that can be configured to convert waste to fuel. Heat exchangers, power generation processes and combustion turbine exhaust apparatus are also provided. Fuel generation processes and generation systems are provided. Reaction media conduit systems as well as processes for servicing reactant media pumps coupled to both inlet and outlet conduits containing reactant media, are also provided.

CROSS REFERENCE TO RELATED APPLICATION

This patent is a divisional of U.S. patent application Ser. No.12/108,438 filed Apr. 23, 2008, entitled “Production Processes, Systems,Methods, and Apparatuses”, which is now abandoned, the entirety of whichis incorporated by reference herein.

TECHNICAL FIELD

The present disclosure relates to production processes and morespecifically to fuel production processes.

BACKGROUND

Each day the need for economically reasonable fuel sources becomesincreasingly important. Similarly the need to dispose of waste in aneconomical yet environmentally friendly method is also highly desirable.The present disclosure provides processes for the conversion ofcarbon-based material such as waste material into fuel, fuel that may beused to power turbines and/or vehicles.

SUMMARY OF THE DISCLOSURE

The present disclosure provides production processes that can includeexposing a carbon-based material to liquid media to form hydrocarbonfuel.

Waste to fuel conversion processes are also provided that can includeproviding a low-moisture carbon-based waste material, and exposing thewaste material to a liquid reaction media under a substantiallyoxygen-free atmosphere within a reactor. The processes can furtherprovide for recovering gaseous hydrocarbon fuel from the reactor.

Waste to fuel processes can also include exposing a solid carbon-basedmaterial to a liquid reaction media to form a hydrocarbon fuel mixture.The fuel mixture can include non-condensable hydrocarbon fuel andcondensable hydrocarbon fuel. Processes can proceed by separating thenon-condensable hydrocarbon fuel from the condensable hydrocarbon fuel.

Waste material processing reactors are provided that can be configuredto convert waste to fuel. The reactors can include a substantiallycolumnar vessel extending along the vessel walls from a base portion toa top portion. An opening can be provided within the top portion of thevessel and the opening can be configured to receive carbon-based wastematerial. A liquid media conduit can be provided that extends from thebase portion to the top portion of the vessel with the conduit beingconfigured to circulate liquid media from within the base portion of thereactor to the top portion of the reactor.

Power generation processes are provided that can include exposing solidcarbon-based material to a liquid reaction media to form non-condensablehydrocarbon fuel. The processes can continue by providing thenon-condensable hydrocarbon fuel to a combustion turbine to generatepower.

Combustion turbine exhaust apparatus are also provided that can includea substantially columnar housing extending along a plane from an inletportion to outlet portion. The apparatus can also include asubstantially columnar exhaust chute within the housing and extendingparallel along the plane with the exhaust chute recessed from the wallsof the housing. The exhaust chute and housing can define a space betweenthe chute and housing within the apparatus. A plurality of heating fluidconduits can be provided within the space and extending along the plane.

Fuel generation processes are provided that can include exposing a solidcarbon-based material to a liquid reaction media to form a mixture ofhydrocarbon fuel and separating the fuel into at least two portions, afirst portion and a second portion. The process can also includeproviding the first portion to a combustion turbine to generate power,and storing the second portion for use as fuel.

Fuel generation systems are provided that can include a reactorconfigured to house a liquid reaction media and receive solidcarbon-based material. Systems can also include a distillation apparatuscoupled to the reactor and configured to receive gaseous hydrocarbonfuel from the reactor. In accordance with example embodiments, thesystem can include a combustion turbine coupled to the distillationapparatus and configured to receive distillate portions from thedistillation apparatus.

Reaction media conduit systems are also provided than can includeconduits coupled to a reaction media pump with a portion of the conduitproximate the pump comprising a jacket defining a volume configured toreceive a refrigerant material.

Processes for servicing reactant media pumps coupled to both inlet andoutlet conduits containing reactant media are also provided with theprocess, including at least partially solidifying portions of thereactant media proximate to the pump and within each of the inlet andoutlet conduits and uncoupling at least a portion of the pump fromeither of the conduits while maintaining a majority of the reactantmedia within the conduits.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the disclosure are described below with reference to thefollowing accompanying drawings.

FIG. 1 is a system according to an embodiment of the disclosure.

FIG. 2A is a portion of the system of FIG. 1 according to an embodimentof the disclosure.

FIG. 2B is a cross section of a portion of the system of FIG. 1according to an embodiment of the disclosure.

FIG. 3 is a cross section of a portion of the system of FIG. 1 accordingto an embodiment of the disclosure.

FIG. 4 is a system according to an embodiment of the disclosure.

FIG. 5 is a system according to an embodiment of the disclosure.

FIG. 6A is a portion of the system of FIG. 5 according to an embodimentof the disclosure.

FIG. 6B is a cross section of a portion of the system of FIG. 5according to an embodiment of the disclosure.

FIG. 7 is a system according to an embodiment of the disclosure.

DESCRIPTION

This disclosure is submitted in furtherance of the constitutionalpurposes of the U.S. Patent Laws “to promote the progress of science anduseful arts” (Article 1, Section 8).

Processes and systems according to the present disclosure are describedwith reference to FIGS. 1-7. Referring first to FIG. 1, a system 10 isdisclosed that includes a reactor 12 configured to receive carbon-basedmaterial 14 and form hydrocarbon fuel 16. According to an exampleimplementation, reactor 12 can house a liquid media. An example liquidmedia comprises a petroleum-based material, and such petroleum-basedmaterial may have a boiling point of at least about 290° C. One examplepetroleum-based material is that provided by 76 Lubricants® (a divisionof ConocoPhillips, 600 N. Dairy Ashford, Houston, Tex. 77079-1175;1-800-762-0942). Example materials from 76 Lubricants® used as liquidmedia can be the 76 Turbine Oil 100-460.

According to example implementations, this liquid media can alsocomprise a zeolite catalyst as well has have a boiling point of at least290° C. This liquid media can be referred to as catalytic liquid mediaand/or catalytic cracking fluid, for example. According to exampleimplementations, the catalyst utilized can be GPI Cat received fromTricat Industries Inc., Schilling Circle, Hunt Valley, Md. 21031 (Tel:(410)785-7900; Fax: (410) 785-7901). The liquid reaction media can alsocomprise a lime material such as a hydrated lime. Example hydrated limesinclude Type S dolometic hydrated lime (Ca(OH)₂*Mg(OH)₂). Such hydratedlime materials can be acquired from the Chemical Lime Company at 3724Hulen Street, Ft. Worth, Tex. 76107. This company can be reached at, forexample, (817) 732-8164. The liquid reaction media in combination witheither one or both of the lime and catalyst can be referred to ascatalytic cracking fluid.

To this liquid media can be added a carbon-based material. Examplecarbon-based materials can comprise cellulose as well as hydrogenmaterials. Example carbon-based materials comprise fluff as well.Fabric, thread, plastic and wood can be used as carbon-based materials.

Materials 14 can include but are not limited to: industrial wasteresidue from commercial cleaners; solvents; lignite; bitumen; earlystages of coal; sawdust; natural and synthetic fabrics; natural andsynthetic fibers; acid alkyl sludges; acid tars; acidic picklingsolutions acidifying agent; acids not otherwise specified; activatedcarbon from chlorine production; adhesives and sealants sludgescontaining halogenated solvents; adhesives and sealants sludges free ofhalogenated solvents; agrochemical wastes; alkaline solutions; alkalisnot otherwise specified; ammonia; animal rendering; aqueous liquid wastefrom gas treatment and other aqueous liquid wastes; aqueous liquid wastefrom oil regeneration; aqueous solvent mixes containing halogens;aqueous solvent mixes free of halogens; aqueous washing liquids; aqueouswashing liquids and mother liquors; bilge oils from inland navigation;bilge oils from jetty sewers; bilge oils from other navigation; bleachsolutions and bleach fixer solutions; boiler dust; brake fluids; calciumarsenate; calcium hydroxidechelating agent; chlorinated emulsions;chlorinated engine, gear and lubricating oils; chlorine dioxideactivator; chlorofluorocarbons, cyanide-free wastes containing chromium;cyanidic (alkaline) wastes containing heavy metals other than chromium;cyanidic (alkaline) wastes which do not contain heavy metals; degreasingwastes containing solvents without a liquid phase; desalter sludges oremulsions; discarded chemicals; electrolyte from batteries andaccumulators; fixer solutions; flue gas dust; fly ash; fly ash and otherflue gas treatment wastes; giberellic acid; grease and oil mixture fromoil/waste water separation; halogenated filter cakes; spent absorbents;halogenated solvents and solvent mixes; halogenated still bottoms andreaction residues; halogenated wastes from dressing and finishing;hydrochloric acid; hydrofluoric acid; ink sludges containing halogenatedsolvents; ink sludges free of halogenated solvents; insulation materialscontaining asbestos; liquid wastes and sludges from metal treatment andcoating of metals (e.g. galvanic processes, zinc coating processes,pickling processes, etching, phosphatizing, alkaline de-greasing);machining sludges; metal hydroxide sludges and other sludges from metalinsolubilization treatment; metallic salts; nitric acid and nitrousacid; non-chlorinated emulsions, oil fly ash; oil spills; oil/waterseparator sludges; oil/water separator solids; oily sludges; organichalogenated solvents, washing liquids and mother liquors filter cakefrom gas treatment; gaseous substances and preparations which areflammable in air at normal pressure; hydraulic oils containing onlymineral oil; hydraulic oils containing PCBs or PCTs; insulating or heattransmission oils and other liquids containing PCBs or PCTs; interceptorsludges; lead batteries; liquid municipal waste; liquid restaurant andfood factory waste; liquid substances and preparations having a flashpoint below 21° C. (including extremely flammable liquids);organochlorinated wood preservatives; organometallic wood preservatives;other chlorinated hydraulic oils (not emulsions); phosphoric andphosphorous acid; photo chemicals; pulp & paper sludge; salts andsolutions containing cyanides; saturated or spent ion exchange resins;skimmings; sludges and solids from tempering processes; sludgescontaining halogenated solvents; sludges containing mercury; sludgescontaining other solvents; sludges from gas treatment; sludges frompaint or varnish removal containing halogenated solvents; sludges frompaint or varnish removal free of halogenated solvents; sludges from zinchydrometallurgy (including jarosite, goethite); sludges or solid wastescontaining halogenated solvents; sludges or solid wastes containingsolvents; soda; solid municipal waste; solid restaurant and food factorywaste; solid substances and preparations which may readily catch fireafter brief contact with a source of ignition and which continue to burnor to be consumed after removal of the source of ignition; solid wastefrom gas treatment; solutions and sludges from regeneration of ionexchangers; solvent based developer solutions; solvent mixes or organicliquids free of halogenated solvents; solvents; solvents and solventmixes free of halogenated solvents; spent activated carbon; spentactivated carbon from flue gas treatment; spent filter clays; spentwaxes and fats; steam degreasing wastes; styrofoam packing; styrofoampeanuts; substances and preparations capable by any means, afterdisposal, of yielding another substance, e.g. a leachate, whichpossesses any of the characteristics listed above; substances andpreparations which may become hot and finally catch fire in contact withair at ambient temperature without any application of energy; substancesand preparations which release toxic or very toxic gases in contact withwater, air or an acid; substances and preparations which, in contactwith water or damp air, evolve highly flammable gases in dangerousquantities; sulphuric acid; sulphuric acid and sulphurous acid;synthetic insulating and heat transmission oils and other liquids;synthetic machining oils; tank bottom sludges; tars and othercarbon-containing wastes from anode manufacture; tires; vitrified wastesand wastes from vitrification; waste acidic solutions; waste adhesivesand sealants containing halogenated solvents; waste adhesives andsealants free of halogenated solvents; waste containing silver fromon-site treatment of photographic waste; waste from agricultural,horticultural, hunting, fishing and aquaculture primary production, foodpreparation and processing; waste from electrolytic refining; waste frommarine transport tank cleaning, containing chemicals; waste from marinetransport tank cleaning, containing oil; waste from natal care,diagnosis, treatment or prevention of disease in humans; waste fromnatural gas purification; waste from railway and road transport tankcleaning, containing chemicals; waste from railway and road transporttank cleaning, containing oil; waste from research, diagnosis, treatmentor prevention of disease involving animals; waste from solvent andcoolant recovery (still bottoms); waste from storage tank cleaning,containing chemicals; waste from storage tank cleaning, containing oil;waste from the pyrolytic treatment of coal; waste from transport andstorage tank cleaning; waste hydraulic oils and brake fluids; waste inkcontaining halogenated solvents; waste ink free of halogenated solvents;waste insulating and heat transmission oils and other liquids; wastemachining emulsions containing halogens; waste machining emulsions freeof halogens; waste machining oils containing halogens (not emulsioned);waste machining oils free of halogens (not emulsioned); materialfinishing wastes such as waste paints and varnish containing halogenatedsolvents, waste paints and varnish free of halogenated solvents; andwastes and sludges from non-ferrous hydrometallurgical processes.

Wastes such as the following can be utilized carbon-based materials:wastes from human or animal health care and/or related research(excluding kitchen and restaurant wastes which do not arise fromimmediate health care); wastes from incineration or pyrolysis ofmunicipal and similar commercial, industrial and institutional wastes;wastes from metal decreasing and machinery maintenance; wastes from oilregeneration; wastes from organic chemical processes; wastes frompetroleum refining, natural gas purification and pyrolytic treatment ofcoal; wastes from power station and other combustion plants; wastes fromshaping (including forging, welding, pressing, drawing, turning, cuttingand filing); wastes from shaping and surface treatment of metals andplastics; wastes from specific physical/chemical treatments ofindustrial wastes (e.g. dechromatation, decyanidation, neutralization);wastes from textile industry such as cleaning and degreasing of naturalproducts; wastes from the leather industry; wastes from the manufacture,formulation, supply and use of coatings (paints, varnishes and vitreousenamels), adhesive, sealants and printing inks; wastes from wastetreatment facilities, off-site waste water treatment plants and thewater industry; waste streams such as wastes from waste water treatmentplants; wastes from water and steam degreasing processes; and wastesfrom wood processing and the production of paper, cardboard, pulp,panels and furniture.

Materials 14 can also include but are not limited to: numerous polymericmaterials such as; rubber, including that from automobile tires; mixedwaste plastics, as small crumbs, or granules; granulate from used tiresand granulated textiles from the tires, including the PVC portion;rubber and motor-car tire foam; pvc; styrofoam.

Materials 14 can also include but are not limited to: waste oils, waxesand fats, for example (including hydraulic oils and transformer oils);used mineral oils, including PCB contaminated transformer oils(pyralene); residues of the vacuum distillation in oil refineries;engine grease and other lubricants; vegetable oils; waste oils; waxesand fats of all kinds including the oil of the electrical changing ofcurrency and hydraulic oils; all refinery arrears, bitumen, tars, etc.;paint; and glycerine.

Materials 14 can also include but are not limited to: agriculturalmaterials (including animal waste products, spoiled food, etc.);biomass; wood products such as carboard; slaughterhouse residues (bones,meat etc); animal waste products and spoiled food sugar plant bagasse;rice plants; shrubs; drugs; wheat; corn; tomatoes; oils and greases;palm waste; lubricants; crop protectant, growth regulator; inorganicpesticides, biocides and wood preserving agents; inorganic woodpreservatives.

Materials 14 can also include but are not limited to: hospital wastematerials; refinery by-products (bitumen, tars, for example); medicalwaste, sterilized; drains and dried biological materials; and autoclavedmaterials.

Materials 14 can also include but are not limited to: biologicalmaterials (wood, vegetables, meat wastes, etc.); household waste;lignite; sludge (paper, water treatment, etc); sewer sludge; papersludge; municipal solid waste; municipal liquid waste; human waste;diapers; clothing; shoes; hair; vegetables; fruits; leather; animalwaste; algae; plants; cherry waste; sludge from wineries; nut waste;food processing waste; coffee grounds; chicken manure; cow manure; hogmanure; animals; forestry waste; farm waste; clippings; and beeattractant.

Materials 14 can also include but are not limited to: shredder residue;automobile components; wood; cellulose; fluff; electrical waste;electronic waste; and paper.

Materials 14 can also include but are not limited to: household wastematerials: chip/snack bags; clothing, textiles, shoes; diapers; foamtake-out containers; frozen good bags; juice boxes; lids, caps, tops;mail; magazines; mixed paper & catalogs; milk boxes; milk cartons;plastic bags; plastic bottles; plastic cups & utensils; plastic foodboxes; plastic food trays; prescription vials; phone books; pillbottles; paint, inks, adhesives and resins; paper bags; paper or frozenfood boxes; paper plates, cups & napkins; construction and demolitionwaste (including road construction); and books.

Materials 14 can also include but are not limited to: “Corrosive”substances and preparations which may destroy living tissue on contact;substances and preparations which present or may present immediate ordelayed risks for one or more sectors of the environment.

Materials 14 can also include but are not limited to: “Explosive”substances and preparations which may explode under the effect of flameor which are more sensitive to shocks or friction than dinitrobenzene.

Materials 14 can also include but are not limited to: “Flammable” liquidsubstances and preparations having a flash point equal to or greaterthan 21° C. and less than or equal to 55° C.

Materials 14 can also include but are not limited to: “Harmful”substances and preparations which, if they are inhaled or ingested or ifthey penetrate the skin, may involve limited health risks.

Materials 14 can also include but are not limited to: “Infectious”substances containing viable micro-organisms or their toxins which areknown or reliably believed to cause disease in man or other livingorganisms.

Materials 14 can also include but are not limited to: “Irritant”non-corrosive substances and preparations which, through immediate,prolonged or repeated contact with the skin or mucous membrane, cancause inflammation.

Materials 14 can also include but are not limited to: “Mutagenic”substances and preparations which, if they are inhaled or ingested or ifthey penetrate the skin, may induce hereditary genetic defects orincrease their incidence.

Materials 14 can also include but are not limited to: “Oxidizing”substances and preparations which exhibit highly exothermic reactionswhen in contact with other substances, particularly flammablesubstances.

Materials 14 can also include but are not limited to: “Teratogenic”substances and preparations which, if they are inhaled or ingested or ifthey penetrate the skin, may induce non-hereditary congenitalmalformations or increase their incidence.

Materials 14 can also include but are not limited to: “Toxic” substancesand preparations (including very toxic substances and preparations)which, if they are inhaled or ingested or if they penetrate the skin,may involve serious, acute or chronic health risks and even death. Toxicwastes such as the following can be utilized as carbon-based materials:Wastes containing arsenic, asbestos from electrolysis, cyanide and heavymetals such as mercury.

Hydrocarbon fuel 16 can comprise non-condensable gasses. The hydrocarbonfuel 16 can also include kerosene and/or diesel fuel as well as naphtha.Example non-condensable gasses can include C1-C4 hydrocarbons as well asCO and H₂. The hydrocarbon fuel can also comprise condensable gasses.Together, these gasses can have a carbon chain length range from C1 toabout C-25 as well as a boiling point less than 382° C. According toexample implementations, the hydrocarbon fuel can be a mixture ofcomponents. This mixture can have a boiling point substantially lessthan the boiling point of the liquid reaction media, or in thealternative, the boiling point of the liquid reaction media can have aboiling point substantially greater than the boiling point of the fuelmixture. Upon exposing the carbon-based material to the liquid reactionmedia, at least a portion of the fuel mixture can be formed. Fuel 16 canbe vaporized upon formation and this vaporized fuel can be provided to aprime mover as described and/or a distillation apparatus as described byexample herein. As stated above, the non-condensable fuel portion of themixture can include C1 to C4 hydrocarbon compounds as well as CO and H₂.According to example implementations, this fuel mixture can comprisehydrocarbon compounds having greater than five carbon atoms. Thecarbon-based material can be substantially dry prior to being exposed tothe liquid media. According to example implementations, the carbon-basedmaterial can have a moisture content less than about 16% (wt./wt.).

Reactor 12 can, according to example implementations, be referred to asa reaction zone, and this reaction zone can house the zeolite catalystreferred to above. According to example implementations, the exposing ofthe material can include exposing the material to the catalyst in thepresence of the liquid media. According to example implementations, thereaction zone can also house the lime and the exposing can furtherinclude exposing the material to the catalyst to the lime in thepresence of the media. Reactor 12 can be configured to house the liquidreaction media and receive solid carbon-based fuel. According to exampleimplementations, the carbon-based material can be provided to reactor 12utilizing a conveyor apparatus associated with reactor 12. The conveyorapparatus can be configured to convey the material to a receivingportion of the reactor.

According to an example implementation, a waste to fuel conversionprocess can be performed utilizing system 10. The process can includeproviding a low moisture carbon-based waste material such as thatdescribed herein, and exposing the waste material to a liquid reactionmedia under a substantially oxygen-free atmosphere within reactor 12.The process can continue by recovering gaseous hydrocarbon fuel 16 fromreactor 12. As stated above, the waste material can comprise biomass,for example, and the low moisture carbon-based waste material cancontain less than 16% (wt./wt.) water. According to exampleimplementations, prior to the exposing of the carbon-based material tothe liquid reaction media can include providing a substantiallyoxygen-free atmosphere above the liquid reaction media within reactor 12and providing the waste material through the atmosphere and into thereaction media within reactor 12. This substantially oxygen-freeatmosphere can include an atmosphere such as nitrogen, for example.According to example implementations, the liquid reaction media can bemaintained at a temperature of at least about 270° C., or between fromabout 270° C. to about 582° C. during the exposing. The liquid reactionmedia can be agitated during the exposing and this agitation can includemechanical agitation, for example.

Referring to FIGS. 2A and 2B, reactor 12 a is shown that includes awaste material processing reactor as disclosed as configured to convertwaste to fuel. This reactor 12 a can include a substantially columnarvessel 12 that extends along vessel walls 21 from a base portion 22 to atop portion 24. Reactor 12 a can have an opening 26 within top portion24 of the vessel. The opening can be configured to receive carbon-basedwaste material, for example. Liquid media 28 can reside within reactor12 a and a liquid media conduit 30 can extend from base portion 22 tothe top portion 24 of vessel 20. According to example implementations,this conduit can be configured to circulate liquid media 28 from baseportion 22 to top portion 24, for example.

Materials of construction used for the systems described herein caninclude but are not limited to carbon steel and/or stainless steel.Implementations can include components constructed of Hastelloy as well.For example, vessel 12 can be constructed of carbon steel material foruse in one embodiment. In other embodiments, vessel 12 can beconstructed of Hastelloy where particularly acidic compounds such asfluoro and chloro compounds are anticipated as part of the feedstock.

Reactor 12 a can be configured with an atmosphere exchange conveyor 32.Conveyor 32 can be configured as an inert gas purged air lock thatincludes tipping valves in combination with rotary valves. Conveyor 32can be coupled to opening 26 and configured to exchange anoxygen-comprising atmosphere associated with waste material with asubstantially oxygen-free atmosphere 34 within reactor 12 a. Reactor 12a can also include an agitation apparatus 36. Example agitationapparatuses include mechanical agitation apparatuses such as propellerconfigured stirring apparatuses. This apparatus can extend to within thevessel and proximate base portion 22 of vessel 20. Reactor 12 a can alsoinclude a hydrocarbon fuel recovery conduit 38. This conduit can be influid communication with the interior of vessel 20, for example.According to example implementations, conduit 30 can extend along vesselwalls 22 on the exterior of the reactor. According to otherimplementations, conduit 30 can be coupled to a heat exchanger 40.According to example implementations, conduit 30 can have an internaldiameter of at least 2.54 cm.

On either or both sides of pump 31 coupled to conduit 30 can be plugapparatus 33. Apparatus 33 can be proximate to pump 31, for example, andcan include an exterior portion of conduit 30 as well a jacket defininga volume between the exterior portion of conduit 30 and the jacket. Thejacket can define a continuous volume surrounding the entire perimeterof the exterior portion of the conduit. Apparatus 33 can be configuredto receive and contain a refrigerant composition within the volumedefined between the jacket and the exterior portion of conduit 30. Anexample refrigerant can include liquid nitrogen.

According to example implementations pump 31, for example, can beserviced by providing refrigerant material to apparatus 33 to at leastpartially solidifying portions of the reactant media proximate the pumpand within each of the inlet and/or outlet conduits. Pump 31 can then beuncoupled from either of the conduits while maintaining a majority ofthe reactant media within the conduits.

Referring to cross section 2B, in conjunction with FIG. 2A, a pluralityof nozzles can extend to within and be in fluid communication with theinterior of vessel 20. According to example implementations, andreferring to FIG. 2, these nozzles can be arranged around portion 24within vessel 20. The nozzles can be configured to provide liquid media28 to within vessel 20 as received from conduit 30. According to exampleimplementations, the nozzles may form a perimeter around opening 26 inportion 24 of vessel 20. Nozzles 42 can be configured to provide media28 in substantially the same direction as the travel of waste materialupon entry into the vessel. According to example implementations, withreference to the configuration of reactor 12 a, this direction can be asubstantially downward direction.

Referring to FIG. 3, an example configuration of heat exchanger 40 isshown as heat exchanger 40 a. Heat exchanger 40 a includes a vessel 50extending along a plane from an inlet portion 52 to an outlet portion54. According to example implementations, the inlet and outlet portionsdefine continuous respective volumes 52 a and 54 a. Vessel 50 caninclude a heating media compartment 56 which is defined by vessel 50 andis located along the plane between inlet portion 52 and outlet portion54. The exchanger also includes a plurality of conduits 58 within vessel50. The individual conduits 58 can extend from the inlet portion volume52 a through the heating media compartment 56 and to outlet portionvolume 54 a. The conduits can be configured to maintain a fluidcommunication between the volumes of the inlet and outlet portions.

According to example implementations, vessel 50 can be substantiallycolumnar and inlet and outlet portions 52 and 54 can be at opposing endsof the columnar vessel 50. According to example implementations, inletand outlet portions 52 and 54 can be configured with removable caps 60.Caps 60 can be affixed to vessel 50 utilizing gasket material, forexample. Each of caps 60 comprise an interior facing surface 62, andthis interior facing surface can define at least a portion of therespective continuous volume 52 a and/or 54 a. Within heat exchanger 40a, each of the individual conduits 58 define an inlet opening 64extending to an outlet opening 66. Each of these inlet and outletopenings 64 and 66 of conduits 58 can be associated respectively witheach of the inlet and outlet portions 54 and 52 of vessel 50. Accordingto example implementations, openings 64 and 66 can be alignedsubstantially normal to face 62 of caps 60. Conduits 58 can also bealigned substantially parallel with interior walls 68 of vessel 50.According to an example implementation, the conduits can be alignedsubstantially normal to the inlet and outlet portions 52 and 54 ofvessel 50. Inlet and outlet portion 52 and 54, respectively, of heatexchanger 40A can define respective inlet and outlet ports 72 and 74respectively. These inlet and outlet ports can be configured to receiveand dispense fluid to be heated. For example, such fluid to be heatedcan include the liquid reaction media for use in reactor 12 of FIG. 1,for example.

Under some process conditions, conduits 58 can become restricted or evenplugged. One or both of caps 60 can be removed and an apparatus used toexpel any or all materials that may be restricting flow through conduits58.

According to example implementations, media compartment 56 can defineinlet and outlet ports 76 and 78. These inlet and outlet ports can beconfigured to receive and dispense a heating fluid. Such heating fluidcan include but is not limited to Thermanol® VP1 heat transfer fluid bySolutia (Solutia, P.O. Box 66760, St. Louis, Mo. 63166-6760; (314)674-1000).

Referring to FIG. 4, system 10 a is provided that includes a reactor 12a configured to receive carbon-based material 14 a and providehydrocarbon fuel 16 a. System 10 a further comprises a distillationapparatus 80 that may be configured to separate portions of hydrocarbonfuel 16 a into discrete hydrocarbon fuel portions 82. According toexample implementations, solid carbon-based material 14 a can be exposedto a liquid reaction media within reactor 12 a to form a hydrocarbonfuel mixture 16 a. This hydrocarbon fuel mixture 16 a can includenon-condensable hydrocarbon fuel and condensable hydrocarbon fuel, forexample. Distillation apparatus 80 can be configured to separate thenon-condensable hydrocarbon fuel from the condensable hydrocarbon fueland form discrete hydrocarbon fuel portions 82. According to exampleimplementations, the liquid reaction media within reactor 12 a can beblanketed with a substantially oxygen-free atmosphere and upon exposingthe carbon-based material to the liquid reaction media, the fuel mixture16 a formed can include at least a portion of this oxygen-freeatmosphere.

Utilizing distillation apparatus 80, at least this portion of theoxygen-free atmosphere can be separated from the non-condensable andcondensable fuels within discrete hydrocarbon fuel portions 82.According to example implementations, distillation apparatus 80 can beconfigured to distill fuel mixture 16 a. Portions 82 of hydrocarbon fuelcan also include naphtha as well as kerosene and diesel fuel portions.Distillation apparatus 80 through fractional distillation and design canbe configured to separate these discrete hydrocarbon fuel portions.

Referring now to FIGS. 5A and 5B, a system 10 b is disclosed thatincludes a reactor 12 b coupled to a generator 90 which is utilized toproduce power 92. Generator 90 can be considered a prime mover withexample prime movers including but not limited to combustion turbines.According to example implementations, carbon-based material 14 b can beexposed to a liquid reaction media within reactor 12 b to form ahydrocarbon fuel mixture 16 a. This hydrocarbon fuel mixture 16 a caninclude non-condensable hydrocarbon fuels, for example. According toexample implementations, this hydrocarbon fuel can be provided togenerator 90. Example combustion turbines include but are not limited togas, liquid, and combination gas/liquid fired combustion turbines.

According to example implementations, the carbon-based material can beprovided to the liquid reaction media in the presence of a substantiallyoxygen-free atmosphere. Fuel mixture 16 a can include this substantiallyoxygen-free atmosphere and prior to providing this fuel mixture 16 a togenerator 90, at least a portion of or all of this substantiallyoxygen-free atmosphere can be removed. Example oxygen-free atmospherescontain nitrogen and/or product vapor such as hydrocarbons, CO, and/orH₂.

According to an example implementation, a mixture comprising fuelmixture 16 a can include the non-condensable hydrocarbon fuel in theatmosphere. The fuel can be separated from the atmosphere and then thisfuel provided to generator 90. An example method for separating thenitrogen-containing atmosphere from the fuel can include distilling thefuel mixture 16 a but in doing so, in providing this process, thehydrocarbon fuel can be substantially free of nitrogen and/or water uponbeing provided to generator 90. According to example implementations,the combustion turbine can be configured to provide at least 2.5megawatts of electricity in the form of power 92. Prior to providingthis fuel mixture 16 a, according to other example implementations,non-condensable hydrocarbon fuel within mixture 16 a can be separatedfrom condensable hydrocarbon fuel and then non-condensable hydrocarbonfuel provided to generator 90 while providing the condensablehydrocarbon fuel for either storage or another source.

Referring to FIG. 5B, system 10 b includes both a distillation apparatus80 and a generator 90 configured to receive hydrocarbon fuel fromdistillation apparatus 80 and generate power 92 therefrom.

Referring to FIGS. 6A and 6B, a generator 90 a is provided having acombustion turbine exhaust apparatus 92. Apparatus 92 can include asubstantially columnar housing 94 extending along a plane from an inletportion 96 to an outlet portion 98. Apparatus 92 can further include asubstantially columnar exhaust chute 100 within housing 94 and extendingparallel along the same plane as housing 94. Exhaust chute 100 can berecessed from walls 102 of the housing of housing 94, the exhaust chute100 and housing defining a space 104 between chute 100 and housing 94.Apparatus 92 further comprises a plurality of heating fluid conduits 106within space 104. Apparatus 92 further comprises dampers 108 associatedwith inlet portion 96 of housing 94. According to exampleimplementations, dampers 108 can be configured to manipulate the flow ofexhaust from the turbine between chute 100 and space 104. Dampers 108can be hinged at 110 proximate the exhaust apparatus 92.

Apparatus 92 can include telescoping portions 99. According to exampleimplementations, telescoping portions 99 can be provided along housing94 between portions 96 and 98 for example.

Referring to FIG. 6B, one cross-section of apparatus 92 is shown.According to example implementations, the plurality of heating conduits106 can comprise separate groups of conduits 112. Individual groups ofconduits can comprise at least conduits within a channel defined bychannel walls 114. These groups can extend between chute 100 and housing94. Channel walls 114 can extend substantially normal between housinginterior surface 102 and chute wall 116. These channel walls and groupscan extend a substantial portion parallel along the plane within space104 between housing wall 102 and chute wall 116. These channels canextend substantially parallel with the walls of the chute and housing.The walls can define a continuous volume 118 extending between inletportion 96 and outlet portion 98 of the apparatus. Groups 112 can bedispersed around a perimeter of the chute and according to exampleimplementations, the groups can be evenly dispersed around the chute.Baffles 120 can extend between groups 112, thereby forcing the exhaustgasses to pass proximate conduits 106.

Referring to FIG. 7, fuel generation system 10 c is provided thatincludes a reactor 12 c configured to house a liquid reaction media andreceive solid carbon-based material via material transfer apparatus 200.System 10 c can include a distillation apparatus 210 coupled to thereactor and configured to receive gaseous hydrocarbon fuel from thereactor. System 10 c can also include a combustion turbine 220 coupledto the distillation apparatus and configured to receive distillateportions from the distillation apparatus. As an example implementation,material transfer apparatus 200 can be configured as a conveyorapparatus associated with reactor 12 c. The conveyor apparatus can beconfigured to convey material to a receiver portion of reactor 12 c.System 10 c can also include a heat exchanger 230 coupled to thereactor. Heat exchanger 230 can be configured to heat the liquidreaction media of reactor 12 c by providing heat from a heat exchangerfluid such as that stored in heat transfer fluid storage tank 232.

According to another example implementation, heat exchanger 230 can becoupled to turbine 220, for example, coupled to the exhaust of turbine220. As an example, the heat exchanger fluid can circulate within theexhaust apparatus of the heat exchanger of the combustion turbine.System 10 c can include a media circulating conduit 234 configured tocirculate liquid reaction media between the reactor and the heatexchanger 230, for example. These conduits can define an accessconfigured to allow for removal of a portion of the media duringcirculating. Filter press 240 can be in fluid communication with thisaccess, for example.

According to example implementations, distillation apparatus 210 canalso include condensers 212. These condensers can be configured toreceive gaseous compounds from apparatus 210 and the condensers can alsobe ranged in serial condenser decanter configurations. Thesecondenser-decanters can be configured to receive gaseous compounds fromdistillation apparatus 210 and return liquid compounds to distillationapparatus 210. According to example implementations, a portion ofdistillation apparatus 210 can include a demister 214 coupled to one ofcondensers 212. This demister can be configured to demist gaseouscompounds received from the condenser and provide these demisted gaseouscompounds directly to combustion turbine 220, for example. In thisconfiguration, condensers 212 can be directly in line betweendistillation apparatus 210 and combustion turbine 214.

According to example implementations, distillation apparatus 210 can beconfigured to separate portions of hydrocarbon fuel 216. These portions216 can include any one or more of fuel oil, kerosene, diesel, naphtha,and/or non-condensable hydrocarbon fuel such as CO and/or H₂. Inaccordance with the utilization of system 10 c, a fuel generationprocess can be utilized that provides for exposing a solid carbon-basedmaterial to a liquid reaction media to form a mixture of hydrocarbonfuel 216. The fuel can be separated into at least two portions, with afirst portion and a second portion. The first portion can be provided toa combustion turbine to generate power, and the second portion can beused for liquid fuel. The substantially dry carbon-based material can beexposed to an oxygen-free reaction zone housed in liquid reaction media,for example, and the separating can include separating a substantiallyoxygen-free atmosphere from the fuel before separating the fuel into twoportions. The first portion of these fuels can include thenon-condensable hydrocarbons, and the second portion can comprise thecondensable hydrocarbons. According to another implementation, the firstportion can comprise non-condensable hydrocarbons and kerosene, and thesecond portion can comprise diesel fuel, for example. This first portioncan be provided to the combustion turbine, and prior to providing to thecombustion turbine, this portion can be vaporized.

According to example implementations, the liquid media can be heatedwith a heat transfer fluid, and the providing of the fuel can includegenerating power as well as an exhaust from the combustion of theturbine wherein the exhaust is used to heat the heat transfer fluid.

In compliance with the statute, embodiments of the invention have beendescribed in language more or less specific as to structural andmethodical features. It is to be understood, however, that the entireinvention is not limited to the specific features and/or embodimentsshown and/or described, since the disclosed embodiments comprise formsof putting the invention into effect. The invention is, therefore,claimed in any of its forms or modifications within the proper scope ofthe appended claims appropriately interpreted in accordance with thedoctrine of equivalents.

The invention claimed is:
 1. A waste to fuel conversion processcomprising: providing a low-moisture carbon-based waste material havingless than 16% wt/wt water; exposing the waste material to a catalyticliquid reaction media under a substantially oxygen-free atmospherewithin a reactor, the catalytic liquid reaction media comprising apetroleum based material having a boiling point of at least about 290°C. and a zeolite catalyst; and recovering gaseous hydrocarbon fuel fromthe reactor.
 2. The process of claim 1 wherein the waste materialcomprises biomass.
 3. The process of claim 1 wherein the exposingcomprises providing a substantially oxygen-free atmosphere above theliquid reaction media and providing the waste material through theatmosphere and into the reaction media.
 4. The process of claim 3wherein the liquid reaction media is maintained at a temperature of atleast about 310° C. during the exposing.
 5. The process of claim 1wherein the liquid reaction media is agitated during the exposing. 6.The process of claim 5 wherein the agitation comprises mechanicalagitation.
 7. The process of claim 1 wherein the gaseous hydrocarbonfuel comprises hydrocarbon compounds ranges in carbon chain length fromC-1 to C-25.
 8. The process of claim 1 wherein the atmosphere comprisesN₂.
 9. The process of claim 1 wherein the waste material is provided tothe reaction media during the exposing via an inert gas purged air lock.10. A waste to fuel process comprising: exposing a solid carbon basedmaterial to a liquid reaction media to form a hydrocarbon fuel mixture,the fuel mixture comprising non-condensable hydrocarbon fuel andcondensable hydrocarbon fuel, wherein the liquid reaction mediacomprises a petroleum based material having a boiling point of at leastabout 290° C. and a zeolite catalyst; and separating the non-condensablehydrocarbon fuel from the condensable hydrocarbon fuel.
 11. The processof claim 10 wherein the liquid reaction media has a boiling pointsubstantially greater than a boiling point of the fuel mixture.
 12. Theprocess of claim 10 wherein upon exposing the solid carbon basedmaterial to the liquid reaction media at least a portion of the fuelmixture is formed.
 13. The process of claim 10 wherein the liquidreaction media is blanketed with a substantially oxygen-free atmosphere,and upon the exposing the fuel mixture comprises at least a portion ofthe atmosphere.
 14. The process of claim 13 wherein the portion of theatmosphere is separated from the non-condensable and condensable fuels.15. The process of claim 10 wherein separating comprises distilling thefuel mixture.
 16. The process of claim 10 wherein the non-condensablefuel comprises C-1 to C-4 hydrocarbon compounds.
 17. The process ofclaim 10 wherein the non-condensable fuel comprises CO and H₂.
 18. Theprocess of claim 10 wherein the condensable fuel comprises hydrocarboncompounds having greater than 5 carbon atoms.